Compressor system with grooved expansion joint

ABSTRACT

The disclosure includes a compressor system having a compressor for compressing and delivering a fluid to a component. First and second conduits are fluidly connected between the compressor and the component. At least one of the conduits is a thin walled conduit having an adaptor end piece connected thereto to transition from a thin wall thickness to a predetermined second wall thickness. A circumferential groove is formed in an outer surface of each of the first and second conduits at a location corresponding to at least the predetermined second wall thickness. An expansion joint clamp is adapted to engage the circumferential grooves and couple the first and second conduits together.

TECHNICAL FIELD

The present application generally relates to industrial air compressor systems and more particularly, but not exclusively, to coupling a thin walled conduit to the system with a grooved expansion joint.

BACKGROUND

Large industrial compressor systems typically have complex design and assembly procedures. Such industrial systems can be difficult to assemble and maintain due to component weight and space claim requirements. Designing conduits with coupling members to minimize size and weight can reduce assembly time as well as enable cost effective maintenance or repair of the compressor system. Some existing systems have various shortcomings relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.

SUMMARY

One embodiment of the present invention is a unique compressor system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for compressor systems with a unique coupling system for thin walled conduits. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a compressor system according to one embodiment of the present disclosure;

FIG. 2 is a perspective view of a portion of the compressor system of FIG. 1 with an enlarged view of a coupling mechanism;

FIG. 3 is a cross sectional view of a first conduit having a thin wall connected to a second conduit with a grooved expansion joint coupling; and

FIG. 4 is an enlarged view of a portion of FIG. 3.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.

Industrial compressor systems that use external fluid to fluid heat exchangers or intercoolers can be heavy, difficult to assemble and typically require a large space claim for component connection assemblies. Fluid heat exchangers as defined herein can be of any type commonly utilized in industrial applications. It should be noted that terms such as intercooler, cooler, inter-stage cooler, aftercooler or the like can be interchanged or substituted and still fall within the broad definition of a heat exchanger as defined by the present disclosure. It should be further understood that the term “fluid” includes any gas or liquid medium used in the compressor system as disclosed herein. Typically, because of the size and weight of industrial components, each of the components are transported separately and assembled on site. It is desirable to minimize the size and weight of connection assemblies such as by use of thin walled conduits or pipes to connect various components of the compressor system. Limited options are available for coupling thin walled conduits when thermal expansion is an operational concern. The present disclosure provides means to reduce the size and complexity of the coupling mechanisms so that thin walled conduits may be used with a compressor system such as that defined herein. For purposes of this disclosure a thin walled conduit is defined as any conduit having a wall thickness that is too thin to structurally support a machined slot or groove formed in an outer surface thereof for a grooved expansion joint clamp to engage therewith. Machining a groove in a thin walled conduit deep enough to support a grooved expansion joint would result in a weakened structure or complete mechanical failure of the conduit. Typical wall thicknesses for thin wall conduits can be found in Nominal Pipe Size (NPS) tables for schedule 5 and schedule 10 conduits. Wall thickness for thin walls can range from 0.035 inches for ⅛ NPS to 0.083 inches for 3½ NPS schedule 5 conduits and from 0.049 inches to 0.120 inches for schedule 10 conduits.

Referring now to FIG. 1, a compressor system 10 is shown therein. The compressor system 10 includes a primary motive source 20 such as an electric motor, an internal combustion engine or a fluid-driven turbine and the like. The compressor system 10 can include a compressor 30 with multi-stage compression and in the exemplary embodiment includes a first stage compressor 32, a second stage compressor 34, and a third stage compressor 36. In other embodiments a different number of compressor stages may be employed with the compressor 30. The compressor 30 can include centrifugal, axial and/or positive displacement compression means. The primary motive source 20 is operable for driving the compressor 30 via a drive shaft 22 to compress fluids such as air or the like. A structural base 12 is configured to support at least portions of the compressor system 10 on a support surface 13 such as a floor or ground and the like. One or more cantilevered extensions or arms 14 can extend from the base 12 and is configured to hold portions of the compressor system 10 suspended above the support surface 13. Portions of the compressed air discharged from the compressor 30 can be transported through more one or more conduits 40, 50, 60, 70 and 80 to one or more intercoolers 100 and/or to another compressor stage. An inlet fluid manifold 90 and an outlet fluid manifold 92 can be fluidly connected to the intercoolers 100 to provide cooling fluid such as water or other liquid coolant to cool the compressed air after discharge from one or more of the compressor stages of the compressor 30. The compressor system 10 can also include a controller 110 operable for controlling the primary motive power source and various valving and fluid control mechanisms (not shown) between the compressor 30 and intercoolers 100.

Referring now to FIG. 2, an enlarged portion of the compressor system 10 is illustrated therein. An intercooler fluid port 200 can be connected to an intercooler 100 proximate an intercooler connecting region 202. The intercooler connecting region 202 can affix the intercooler fluid port 200 to the intercooler 100 via weld, braze, or other mechanical fastening means as known to those skilled in the art. The intercooler fluid port 200 can include a port coupling region 204 positioned on an opposing end of the intercooler fluid port 200 from the intercooler connecting region 202. In this exemplary embodiment the intercooler fluid port 200 includes an elbow or bend 203, however, in other embodiments the intercooler fluid port can substantially extend straight away from a sidewall of the intercooler 100. A fluid conduit 60 can include a connecting end portion 206 extending to a coupling region 208 formed between the intercooler port 200 and the connecting end portion 206 of the fluid transfer conduit 60. The fluid conduit 60 can include a thin wall 210 which defines the conduit as a thin walled conduit. The fluid coupling region 208 can include a grooved expansion joint clamp 209 operable for connecting the intercooler fluid port 200 with the fluid transfer conduit 60 as will be described in more detail below. In this this exemplary embodiment, the expansion joint claim 209 connects the fluid transfer conduit 60 to the fluid port 200, however it should be understood that other connections of thin walled conduits are contemplated by this disclosure.

Referring now to FIGS. 3 and 4, an enlarged cross-sectional view of the coupling region 208 of the conduit 60 and the intercooler fluid port 200 is illustrated. In this example, the fluid transfer conduit 60 is formed as a thin walled structure. In other embodiments both the conduit 60 and fluid port 200 can be thin walled structures. As explained above, a thin wall as defined herein includes a conduit or a pipe having a wall thickness that is too thin to machine grooves or the like therein for a grooved expansion clamp to engage therewith and couple a pair of conduits together. The thickness of the thin wall 210 is defined by the distance between an inner surface 211 and an outer surface 213 of the thin wall 210. The connecting end portion 206 can include an adaptor fitting 207 that is connected to the thin wall portion of the conduit 60. The adaptor fitting 207 can be attached by a weld 255 or other mechanical means known to those skilled in the art. The adaptor 207 provides a transition from a thin wall 210 to a second wall thickness 214 defined as the distance between an inner surface 213 and an outer surface 215 thereof. The second wall thickness 214 is defined as a wall that is thick enough to receive a machined groove for an expansion joint coupling and remain structurally sound. The connecting end portion 206 includes a tapered transition portion 212 that widens from the thin wall 210 of the conduit 60 to the second wall thickness 214 at a coupling end portion 216. The coupling end portion 216 includes a second wall thickness to 214 that is structurally capable of receiving a slot or groove 200 formation therein. The slot or groove 220 (best seen in FIG. 4) can be formed in the coupling portion 216 of the adaptor 207. The slot 220 can be formed in any traditional manner as known to those skilled in the art such as by way of example and not limitation a milling machine or a lathe and the like. The connecting end portion 206 can be attached to the thin walled portion of the conduit 60 via a weld joint 255 or a brazed joint as described previously.

The intercooler fluid port 200 can include a wall 223 defined from an inner surface 225 to an outer surface 227. The wall 223 can be a thin wall in which case an adapter such as the adapter 207, would necessarily need to be connected thereto. Optionally the wall 223 can be formed with a wall having a thickness sufficient to receive a machined slot 222 (best seen in FIG. 4) therein. An expansion clamp 209 can engage the slots 220, 222 of the fluid conduit 60 and the intercooler fluid port 200 so as to permit a releasable connection there between. The expansion clamp 209 permits the conduits to move relative to one another without binding or potentially causing material failure. The expansion clamp 209 can include a threaded fastener 221 on opposing sides to clamp two halves (not shown) of the clamp 209 together. A first o-ring seal 250 can be positioned between the clamp 209 and a portion and the outer surface 215 of the connecting end portion 206 to form a fluid tight seal therebetween. Likewise, a second O-ring seal 252 can be positioned between the outer surface 227 of the intercooler fluid port 200 and the clamp 209 to provide a fluid type connection therebetween.

Referring now to FIG. 4, an enlarged exploded view of the connecting or coupling region 208 of the conduits 60, 200 and the expansion clamp 209 is illustrated. The expansion clamp 209 can include a first leg extension 230 that is operably engageable with the slot 220 of the connecting end portion 206 of the thin walled conduit 60 and a second leg extension 232 that is operably engageable with the slot 222 formed in the end of the intercooler fluid port 200. The slots 220, 222 provide for a path for the leg extensions 230, 232 of the clamp 209 to slide along. The conduits 60, 200 can move relative to the clamp 209 and to one another along a longitudinal or axial direction defined by axis 270 (See FIG. 3). The slot 220 can include a first abutment wall 231 and a second abutment wall 233 to define the bounds for the leg extension 230 to slide therebetween. Likewise, the slot 222 formed in the intercooler fluid port 200 can include a first abutment 235 and second abutment 237 for the leg extension 232 of the expansion clamp 209 to slide therebetween.

The clamp 209 can include a first o-ring groove 260 on one side and a second o-ring groove 262 on the other side to receive the o-rings 250, 252 therein so as to provide a fluid tight seal between the clamp 209 and each conduit 60, 200 respectively. It should be understood that other forms of fluid sealing arrangement can be used and remain within the teachings of the present application. For example, a single seal can be attached between the clamp and extend across the interface region of the ends of the conduit 60, 200 respectively to form a fluid tight seal therewith. In yet another embodiment the conduits can include grooves to house seals such as O-rings therein as opposed to the clamp housing the O-ring seals.

In operation the compressor system is configured to provide compressed air at a desired temperature and pressure to external systems. The compressor systems can be used in any industrial application including but not limited to automobile manufacturing, textile manufacturing, process industries, refineries, power plants, mining, material handling, etc. The controller permits user input to define parameters such as pressure, temperature and mass flow rate. The controller will send command signals to the motor to rotate at a desired operating speed in order to drive the one or more compressors and control various valving to control airflow rate and coolant flow rate. In the illustrative example, the compressor system includes a three-stage centrifugal compressor system, however, the system can operate with other types of compressors and/or with more or less stages of compressors. One or more intercoolers can be fluidly coupled to each compressor stage such that after air is compressed through the first stage the air can be transported through a first intercooler and can be cooled to a desired temperature via a heat transfer mechanism such as conduction and convection in tube type heat exchangers. The compressed air can then be transported into a second stage compressor where the air further compressed and necessarily heated to a higher temperature through a thermodynamic process. The second stage compressed air can then be routed through a second intercooler to cool the air to desired temperature while remaining at or close to the compressor outlet pressure of the second stage compressor. The cooled compressed air exiting from the second intercooler can then be transported to a third stage compressor where it is compressed to a final desired pressure and then subsequently routed to a third stage intercooler to bring the temperature of the final discharged air pressure to the desired temperature for delivery to a final subsystem. In one form the compressors can be centrifugal compressors, however, other forms of compression can include axial flow compressors, piston compressors or other positive displacement compressors can be used under the teachings of the present disclosure.

The expansion groove clamp connection with at least one thin walled conduit provides means for facilitating positional variation of components due to mechanical dimensional tolerance stack-up that occurs during assembly and/or for thermal expansion growth between various components due to temperature gradients caused by variable heating and cooling of the components of the compressor system. The expansion groove clamp used in combination with at least one thin walled conduit also provides means for coupling of fluid conduits in the compressor system in a manner that minimizes space claim and weight which can facilitate ease of assembly and maintenance of said system. As such, the conduit coupling means disclosed herein provides a system that remains structurally sound and minimizes potential for mechanical failure due to loads caused by mechanical constraints and thermal loading during operation of the compressor system.

Material selection for the fluid conduits, coupling members and other components of the compressor system can include various forms of metal, metal alloys, composites, ceramics, or plastics as desired. Metals can include, but are not limited to aluminum, steel, iron, super alloys and combinations thereof. The metal material may further be formed from cast, wrought, or sheet stock.

In one aspect the present disclosure includes a compressor system comprising: a compressor for compressing a fluid; a component in fluid communication with the compressor for receiving compressed fluid; first and second conduits fluidly connecting the compressor to the component, wherein at least one of the conduits is a thin walled conduit; an adaptor end piece connected to an end of the at least one thin walled conduit, wherein the adaptor end piece transitions from a thin wall thickness to a predetermined second wall thickness; a circumferential groove formed in an outer surface of each of the first and second conduits at a location corresponding to the predetermined second wall thickness; and an expansion joint clamp adapted to engage the circumferential grooves and couple the first and second conduits together.

Refining aspects include an adapter end piece having an angled inner wall extending from the thin wall of the thin walled conduit and the second wall thickness; wherein the expansion joint clamp permits relative movement between the first and second conduits; wherein the clamp includes a pair of circumferential leg extensions; wherein the leg extensions are positioned within the grooves of the first and second conduits; wherein the leg extensions are constructed to slide axially along a width of each groove; wherein each groove includes a pair of side walls to define opposing abutments; wherein one end of each conduit is permanently attached to a compressor component; wherein the component is an intercooler; and wherein the conduits are structured to receive relatively high temperature fluid flow therethrough.

Another aspect of the present disclosure includes an apparatus comprising: a compression system configured to compress a fluid; a first conduit fluidly connectable to the compression system; a second conduit fluidly connectable to the first conduit; wherein at least one of the first and second conduits are defined by a circumferential thin walled structure; an adaptor end connected to at least one of the first and second conduits having a thin walled structure, the adaptor having a tapered inner wall that transitions from a thin wall to a second wall thickness, wherein the second wall thickness is sufficient to support a circumferential slot formed in the outer surface thereof; a circumferential slot formed in the outer surface of each of the first and second conduits at a location having a wall thickness at least equivalent to the second wall thickness; and an expansion joint coupling engageable with the slots of the first and second conduits and operable to connect the first and second conduits together.

Refining aspects include a multi-stage centrifugal compressors driven by a motive source; further comprising: an intercooler fluidly connected to one of the first and second conduits; wherein the fluid includes air; further comprising: a fluid seal engaged with the coupling to form a fluid tight seal between the first and second conduits; wherein the expansion joint coupling permits relative movement between the first and second wherein the expansion joint coupling includes a pair of circumferential leg extensions; wherein the leg extensions are configured to engage the slots formed in the first and second conduits; wherein the leg extensions are constructed to slide between sidewall abutments along a width of each slot.

Another aspect of the present disclosure includes a method comprising: welding an adaptor to an end of a thin walled conduit, wherein the adaptor includes a portion having a second wall thickness greater than the thin walled conduit; forming an outwardly facing groove in the adaptor proximate the portion having the second wall thickness; forming an outwardly facing groove in a second conduit; connecting the first and second conduits with an expansion groove clamp positioned within the grooves of the first and second conduits; generating heated fluid with a compressor system; transporting the heated fluid through the first and second conduit; and moving the conduits relative to the clamp in response to variable thermal loading.

A refining aspect includes sliding a portion of the clamp along a width of the grooves formed in each of the conduits; wherein the compression system includes a centrifugal compressor fluidly connected to at least one intercooler with the first and second conduits; and further comprising: forming a fluid tight seal between the first and second conduits.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.

Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 

What is claimed is:
 1. A compressor system comprising: a compressor for compressing a fluid; a component in fluid communication with the compressor for receiving compressed fluid; first and second conduits fluidly connecting the compressor to the component, wherein at least one of the conduits is a thin walled conduit; an adaptor end piece connected to an end of the at least one thin walled conduit, wherein the adaptor end piece transitions from a thin wall thickness to a predetermined second wall thickness; a circumferential groove formed in an outer surface of each of the first and second conduits at a location corresponding to the predetermined second wall thickness; and an expansion joint clamp adapted to engage the circumferential grooves and couple the first and second conduits together.
 2. The compressor system of claim 1, wherein the adapter end piece includes an angled inner wall extending from the thin wall of the thin walled conduit and the second wall thickness.
 3. The compressor system of claim 1, wherein the expansion joint clamp permits relative movement between the first and second conduits.
 4. The compressor system of claim 1, wherein the clamp includes a pair of circumferential leg extensions.
 5. The compressor system of claim 4, wherein the leg extensions are positioned within the grooves of the first and second conduits.
 6. The compressor system of claim 4, wherein the leg extensions are constructed to slide axially along a width of each groove.
 7. The compressor system of claim 4, wherein each groove includes a pair of side walls to define opposing abutments.
 8. The compressor system of claim 1, wherein one end of each conduit is permanently attached to a compressor component.
 9. The compressor system of claim 1, wherein the component is an intercooler.
 10. The compressor system of claim 1, wherein the conduits are structured to receive relatively high temperature fluid flow therethrough.
 11. An apparatus comprising: a compression system configured to compress a fluid; a first conduit fluidly connectable to the compression system; a second conduit fluidly connectable to the first conduit; wherein at least one of the first and second conduits are defined by a circumferential thin walled structure; an adaptor end connected to at least one of the first and second conduits having a thin walled structure, the adaptor having a tapered inner wall that transitions from a thin wall to a second wall thickness, wherein the second wall thickness is sufficient to support a circumferential slot formed in the outer surface thereof; a circumferential slot formed in the outer surface of each of the first and second conduits at a location having a wall thickness at least equivalent to the second wall thickness; and an expansion joint coupling engageable with the slots of the first and second conduits and operable to connect the first and second conduits together.
 12. The apparatus of claim 11, wherein the compressor system includes multi-stage centrifugal compressors driven by a motive source.
 13. The apparatus of claim 11, further comprising: an intercooler fluidly connected to one of the first and second conduits.
 14. The apparatus of claim 11, wherein the fluid includes air.
 15. The apparatus of claim 11, further comprising: a fluid seal engaged with the coupling to form a fluid tight seal between the first and second conduits.
 16. The apparatus of claim 11, wherein the expansion joint coupling permits relative movement between the first and second conduits.
 17. The apparatus of claim 11, wherein the expansion joint coupling includes a pair of circumferential leg extensions.
 18. The apparatus of claim 17, wherein the leg extensions are configured to engage the slots formed in the first and second conduits.
 19. The apparatus of claim 17, wherein the leg extensions are constructed to slide between sidewall abutments along a width of each slot.
 20. A method comprising: welding an adaptor to an end of a thin walled conduit, wherein the adaptor includes a portion having a second wall thickness greater than the thin walled conduit; forming an outwardly facing groove in the adaptor proximate the portion having the second wall thickness; forming an outwardly facing groove in a second conduit; connecting the first and second conduits with an expansion groove clamp positioned within the grooves of the first and second conduits; generating heated fluid with a compressor system; transporting the heated fluid through the first and second conduit; moving the conduits relative to the clamp in response to variable thermal loading.
 21. The method of claim 20, wherein the moving includes sliding a portion of the clamp along a width of the grooves formed in each of the conduits.
 22. The method of claim 20, wherein the compression system includes a centrifugal compressor fluidly connected to at least one intercooler with the first and second conduits.
 23. The method of claim 20, further comprising: forming a fluid tight seal between the first and second conduits. 